Composite forming post-manufacture: reducing complexity and de-risking manufacture

Composite forming post-manufacture: reducing complexity and de-risking manufacture


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Abstract. Forming is a high-risk operation as the deformation of precursors, such as preforms or prepregs, is difficult to control. Aiming at de-risking manufacturing and improving processing logistics, a new forming concept is presented involving pre-structuring, i.e. producing fully cured flat structure with integrated formable hinge regions, and assembly, where the part is given the targeted shape using localised forming in the hinge regions. Such a technique becomes feasible if (a) the hinges are produced with the aid of covalent adaptive networks (CANs, cross-linked polymers that can flow when heated above a certain temperature), (b) the excess fibre length (that can occur in the process of forming) is incorporated at the pre-structuring stage. Hence, we pursue an idea of multi-matrix continuously-reinforced composites (MMCRC) with embedded fibre path features, where the main body of composites structure is produced with a conventional epoxy matrix and the hinged areas are produced with reformable CANs. The current paper explores the potential and limitations of this technology in manufacturing trials. It is demonstrated that the presented concept can yield high quality solutions. It is highlighted that an improved manufacturing procedure using specially designed and portable machinery would enable application of the MMCRC technology in the field, facilitating repair and efficient transportation.

Composites, Modular Forming, Multi-Matrix Systems, Post-Manufacture Forming

Published online 4/24/2024, 9 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: PALUBISKI Dominic R., LONGANA Marco L., DULIEU-BARTON Janice M., HAMERTON Ian, IVANOV Dmitry S., Composite forming post-manufacture: reducing complexity and de-risking manufacture, Materials Research Proceedings, Vol. 41, pp 440-448, 2024


The article was published as article 49 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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